U.S. patent number 6,303,248 [Application Number 09/332,765] was granted by the patent office on 2001-10-16 for solderless battery pack.
Invention is credited to Roland K. Peterson.
United States Patent |
6,303,248 |
Peterson |
October 16, 2001 |
**Please see images for:
( Certificate of Correction ) ** |
Solderless battery pack
Abstract
A solderless battery pack. The pack has a generally thin wall
cell body portion with two tubular segments each adapted to hold a
plurality of batteries. An upper end cap and a lower end cap are
provided for fitting tightly over the upper and lower ends of the
cell body portion, respectively. The end caps are compressingly
engaged to make electrical connection with the terminals of the
uppermost and the lowermost batteries by use of opposing all-thread
fasteners, or more preferably, by use of shrink wrap tubing. More
preferably, instead of all-thread fasteners, a filament type
strapping tape is utilized for wrapping the battery pack around a
longitudinal exist to tightly compress batteries in each column of
batteries. Then, the tape is covered by and further compressed with
a tightly compressing shrink wrap material.
Inventors: |
Peterson; Roland K. (Seattle,
WA) |
Family
ID: |
27367533 |
Appl.
No.: |
09/332,765 |
Filed: |
June 14, 1999 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
095776 |
Jun 10, 1998 |
6187470 |
|
|
|
Current U.S.
Class: |
429/177; 429/100;
429/157; 429/159; 429/99 |
Current CPC
Class: |
H01M
50/213 (20210101); H01M 50/572 (20210101); H01M
6/42 (20130101); H01M 2200/30 (20130101) |
Current International
Class: |
H01M
2/10 (20060101); H01M 6/00 (20060101); H01M
2/20 (20060101); H01M 6/42 (20060101); H01M
6/50 (20060101); H01M 2/34 (20060101); H01M
002/02 (); H01M 002/10 () |
Field of
Search: |
;429/177,100,99,159,157 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Article, Model Electronics Corp. "Solderless Power Tube", by Jim
Petro, S & E Modeler Sailplane & Electric, Oct./Nov., 1998,
vol. 3, No. 6, pp. 4-6..
|
Primary Examiner: Maples; John S.
Parent Case Text
This application is based on, and priority is claimed from, and a
C-1-P of prior co-pending U.S. patent application Ser. No.
09/095,776, filed Jun. 10, 1998, now U.S. Pat. No. 6,187,470, which
is based on and claims priority from U.S. Provisional Patent
Application Serial No. 60/049,413, filed Jun. 10, 1997, the
disclosures of each of which are incorporated herein by this
reference.
Claims
What is claimed is:
1. A battery pack for holding a plurality of battery cells, each of
said battery cells of the shape having an elongate body portion
with an outer surface portion and opposing first and second ends,
each of said first and second ends further comprising either a
positive electrical terminal or a negative electrical terminal,
said battery pack comprising:
(a) a bottom end cap, said bottom end cap
(i) shaped to fit along a portion of said outer surface portion of
at least one of said plurality of battery cells, so as to receive
therein in snug fitting fashion, transverse cross-sectionwise, at
least some of said outer surface of said elongate body portion of
said at least one of said plurality of battery cells,
(ii) further comprising a first electrical contact, said first
electrical contact adapted to provide electrical continuity with a
lower end of a lowermost of said plurality of battery cells;
(b) a top end cap, said top end cap
(i) shaped to fit along a portion of said outer surface portion of
at least one of said plurality of battery cells, so as to receive
therein in snug fitting fashion, transverse cross-sectionwise, at
least some of said outer surface of said elongate body portion of
said at least one of said plurality of battery cells;
(ii) further comprising
(A) a second electrical contact, said second electrical contact
adapted to provide electrical continuity with an upper end of an
uppermost of said plurality of battery cells;
(c) an outer surface cover, said outer surface cover comprising a
shrink wrap material, said shrink wrap material sized and shaped,
when fully treated to its final shrunk size and shape, to
compressingly engage and urge said top end cap and said bottom end
cap toward each other, so as to compressingly engage battery cells
spaced between said top end cap and said bottom end cap.
2. A battery pack for holding a plurality of battery cells, said
battery cells of the shape having an elongate body portion with an
elongate body portion with an outer surface portion and opposing
first and second ends, each of said first and second ends further
comprising either a positive electrical terminal or a negative
electrical terminal, said battery pack comprising:
(a) a bottom end cap, said bottom end cap
(i) shaped to fit along a portion of said outer surface portion of
each of a transversely adjacent pair of said battery cells, so as
to receive therein in snug fitting fashion, transverse
cross-sectionwise, at least some of said outer surface of said
elongate body portion of each one of said adjacent pair of said
battery cells,
(ii) further comprising a first electrical contact, said first
electrical contact adapted to provide electrical continuity between
a first end of a first one of said pair of battery cells and a
second end of a second one of said pair of adjacent battery
cells;
(b) a top end cap, said top end cap
(i) shaped to fit along a portion of said outer surface portion of
each one of a pair of transversely adjacent battery cells, so as to
receive therein in snug fitting fashion, transverse
cross-sectionwise, at least some of said outer surface of said
elongate body portion of each one of said pair of adjacent battery
cells, and
(ii) further comprising
(A) a second electrical contact, said second electrical contact
adapted to provide electrical continuity to an electrical terminal
on said first end of one of said pair of adjacent battery cells,
and
(B) a third electrical contact at the upper reaches thereof, said
third electrical contact adapted to provide electrical continuity
to an electrical terminal on said second end of one of said pair of
adjacent battery cells;
(c) an outer surface cover, said outer surface cover comprising a
shrink wrap material, said shrink wrap material sized and shaped,
when fully treated to its final shrunk size and shape, to
compressingly engage and urge said top end cap and said bottom end
cap toward each other, so as to compressingly engage battery cells
spaced between said top end cap and said bottom end cap.
3. The battery pack as set forth in claim 2, wherein said battery
cells are provided in a first column and a second column, and
wherein the number of batteries is the same in each column.
4. The battery pack as set forth in claim 2, wherein a number P of
pairs of battery cells is provided, and wherein P is a positive
integer equal to one or more.
5. A battery pack for holding a plurality of batteries, said
battery pack comprising:
(a) a first cell holder sleeve body, said first cell holder sleeve
body comprising a first tubular segment adapted to receive therein
a plurality of elongate battery cells, said plurality of elongate
batteries in said first tubular segment having a first lower end
battery and a first upper end battery;
(b) a second cell holder sleeve body, said second cell holder
sleeve body comprising a second tubular segment adapted to receive
therein a plurality of elongate battery cells, said plurality of
elongate batteries in said second tubular segment having a second
lower end battery and a second upper end battery;
(c) a bottom end cap, said bottom end cap
(i) shaped to fit along a portion of said outer surface of each of
a transversely adjacent pair of said battery cells, so as to
receive therein in snug fitting fashion, transverse
cross-sectionwise, at least some of said outer surface of said
elongate body portion of each one of said adjacent pair of said
battery cells,
(ii) further comprising a first electrical contact, said first
electrical contact adapted to provide electrical continuity between
a first end of a first one of said pair of battery cells and a
second end of a second one of said pair of adjacent battery
cells;
(d) a top end cap, said top end cap
(i) shaped to fit along a portion of said outer surface of each one
of a pair of transversely adjacent battery cells, so as to receive
therein in snug fitting fashion, transverse cross-sectionwise, at
least some of said outer surface of said elongate body portion of
each one of said pair of adjacent battery cells, and
(ii) further comprising
(A) a second electrical contact, said second electrical contact
adapted to provide electrical continuity to an electrical terminal
on said first end of one of said pair of adjacent battery cells,
and
(B) a third electrical contact at the upper reaches thereof, said
third electrical contact adapted to provide electrical continuity
to an electrical terminal on said second end of one of said pair of
adjacent battery cells;
(e) an outer surface cover, said outer surface cover comprising a
shrink wrap material, said shrink wrap material sized and shaped,
when fully treated to its final shrunk size and shape, to
compressingly engage and urge said top end cap and said bottom end
cap toward each other, so as to compressingly engage battery cells
spaced between said top end cap and said bottom end cap.
6. The battery pack as set forth in claim 2 or in claim 5,
wherein
(a) said top end cap further comprises a central portion having
spaced apart first and second guide passageways;
(b) said bottom end cap further comprises a central portion having
spaced apart third and fourth guide passageways, said third and
fourth guide passageways located in complementary opposing fashion
to said first and second guide passageways, and
(c) said battery pack has a longitudinal axis, and
(d) further comprising a first and a second compression stay, said
first and second compression stay spaced apart between opposing
central portions of said top end cap and said bottom end cap and
running along said longitudinal axis of said battery pack, said
first compression stay extending between a first and a third guide
passageway, and said second compression stay extending between a
second and a fourth guide passageway.
7. The battery pack as set forth in claim 6, wherein said first or
said second compression stay comprises
(a) a first and a second retaining nut,
(b) an all-thread bolt adapted for being secured in close fitting
relationship through one of said guide passages in said top end cap
and through one of said guide passages in said bottom end cap, said
all thread bolt fastened by a first retaining nut at the upper end
of said all thread bolt and located above said top end cap and by a
second retaining nut located below said bottom end cap at the lower
end of said all thread bolt, said all-thread bolt adapted to
compress said top end cap toward said bottom end cap.
8. The battery pack as set forth in claim 7, wherein said first
compression stay comprises a first all-thread bolt with
complementary retaining nuts, and said second compression stay
comprises a second all-thread bolt with complementary retaining
nuts, and wherein said first and said second all-thread bolts are
of differing diameter.
9. The battery pack as set forth in claim 1, or in claim 2, or in
claim 5, wherein said a first cell holder sleeve body, or said
second cell holder sleeve body, comprises a see-through shrink wrap
material.
10. The battery pack as set forth in claim 1, or in claim 2, or in
claim 5, wherein said outer surface cover comprises a see-through
shrink wrap material.
11. The battery pack as set forth in claim 1, or in claim 2, or in
claim 5, further comprising a compression tape portion, said
compression tape portion loop extending longitudinally along a
front and along a back of said battery pack, over said top end cap,
and below said bottom end cap, so as to compressingly confine and
secure said batteries between said top end cap and said bottom end
cap.
12. The battery pack as set forth in claim 11, wherein said
compression tape portion comprises strapping tape.
13. The battery pack as set forth in claim 11, wherein said
compression tape portion comprises a continuous tape portion
extending from inside said bottom end cap, around the front of said
bottom end cap, below the bottom of said bottom end cap, up the
rear of said bottom end cap, longitudinally along the rear of said
battery pack, along the rear of said top end cap, above the top of
said top end cap, down the front of said top end cap, down the
front of said battery pack, down the front of said bottom end cap
over the tape portion already provided, across the bottom of said
bottom end cap over the tape portion already provided, and up the
rear of said bottom end cap over the tape portion already
provided.
14. The battery pack as set forth in claim 1, or in 2, or in claim
5, wherein each of said batteries in said battery pack comprises a
rechargeable battery.
15. The battery pack as set forth in claim 14, wherein said
rechargeable battery selected from the group consisting of (a)
nickel-cadmium batteries, (b) nickel metal hydride batteries, and
(c) lithium batteries.
16. The battery pack as set forth in claim 1, or in claim 2, or in
claim 5, wherein said battery cells are selected from the size
consisting of (a) AA, (b) AAA, (c) C, and (d), sub-C.
17. The battery pack as set forth in claim 1, or in 2, or in claim
5, further comprising a phantom battery portion, said phantom
battery portion comprising a substantially annular foam cell
portion in a substantially battery shaped configuration, said
phantom cell battery portion located at an upper most battery
location in one of said first or second columns.
18. The battery pack as set forth in claim 17, wherein said phantom
battery portion further comprises an annular tubular central
portion, said annular tubular central portion adapted to receive
therethrough said first electrical connector.
19. The battery pack as set forth in claim 1, or claim 2, or claim
4, further comprising, affixed to said outer shrink wrap cover, a
strip of hook and loop fastener.
Description
TECHNICAL FIELD OF THE INVENTION
This invention relates to novel battery holders, especially for
holding a plurality of battery cells, and to methods of using the
same, particularly for small electric powered vehicles such as
model trucks and model aircraft.
BACKGROUND OF THE INVENTION
In the use of batteries to power electrical toys and tools, such as
small electrically powered model cars or airplanes, it is often
desirable to gang seven to ten rechargeable cells together to
provide the desired amount of power. In fact, at this time, it
quite is popular to use rechargeable cells of about 1.2 volts each,
assembled in battery packs ranging from about 4 cells to about 12
cells per battery pack. At present, for use in model cars, the use
of 6 cells per battery pack is preferred. In model aircraft, the
use of from 8 to about 10 cells per battery pack is presently
preferred.
In spite of the various schemes which have so far been offered to
the marketplace for holding multiple batteries together in a pack,
a continuing and growing demand exists for a simple, inexpensive
method which can be used to maximize battery output, and to
preserve and enhance the reliability of the batteries in the pack,
as well as to enhance the service life of batteries between
recharge cycles. A particular problem often seen in various prior
art battery holders is the presence of spot welded or soldered
junctions. Such junctions are usually somewhat resistant to
electrical conduction, resulting in heating of the junction,
sometimes to unacceptably high levels, which needlessly dissipates
and wastes power.
As will be evident to those familiar with model cars, trucks, and
aircraft, and to whom this specification is particularly addressed,
a battery holder which effectively eliminates the loss of energy in
soldered, welded, or other inefficient electrical joints would be
of great benefit in increasing the operating life of such battery
packs, when compared with battery holders which are currently in
widespread use. Moreover, in competitive applications, such as
model auto, boat, or aircraft races, a battery pack which can
increase the output power and/or battery discharge cycle time,
would be a welcome addition to the competitor's arsenal.
OBJECTS, ADVANTAGES, AND FEATURES OF THE INVENTION
From the foregoing, it will be apparent to the reader that one
important and primary object of the present invention resides in
the provision of a novel battery pack for ganging together a
plurality of cells in a manner that maximizes the efficiency of
extracting power from the battery cells in the pack.
Another important objective of the invention is to eliminate
battery power loss due to resistive heating in spot welds or
soldered joints, by providing a battery pack which avoids using
such means for forming electrical connections.
Other important but more specific objects of the invention reside
in the provision of novel battery packs which:
provide forces for strongly urging adjacent battery terminals
together in electrical contacting fashion;
provide a protective cover to house the battery packs;
are highly efficient in supplying electrical power from
rechargeable battery cells.
Other important objects, features, and additional advantages of my
invention will become apparent to the reader from the foregoing and
from the appended claims, and as the ensuing detailed description
and discussion proceeds in conjunction with the accompanying
drawing.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a front elevation view of one embodiment of my battery
pack, with a transparent shrink wrap cell holder sleeve body for
each of two battery columns, a top and a bottom end cap each with
electrical contacts, utilizing threaded rod type compression stays,
shown with the battery pack holding ten battery cells and having an
outer shrink wrap cover for tightly urging the battery cells
together for efficient electrical supply from the battery pack.
FIG. 2 is an exploded rear perspective view of the battery pack
just illustrated in FIG. 1, now showing between the top and bottom
end caps a first shrink wrap cell holder sleeve which contains a
first column of battery cells, a second shrink wrap cell holder
sleeve which contains a second column of battery cells, an outer
shrink wrap cover for the battery pack, and a first and a second
threaded compression stay with retaining nuts for securing the
battery pack together.
FIG. 3 is a front cross-sectional view of the top end of my battery
pack, showing the electrical connection to positive terminals of a
battery cell on one side and to a negative terminals of a battery
cell on the other side, as well as the upper end of first shrink
wrap cell holder sleeve which contains a first column of battery
cells, the upper end of a second shrink wrap cell holder sleeve
which contains a second column of battery cells, and the upper
portion of an outer shrink wrap cover for the battery pack.
FIG. 4 is a front cross-sectional view of the bottom end of my
battery pack, showing the electrical connector bar used in the
bottom end cap to electrically connect a first battery column with
a second battery column, as well as the bottom end of a first
shrink wrap cell holder sleeve which contains a first column of
battery cells, the bottom end of a second shrink wrap cell holder
sleeve which contains a second column of battery cells, and the
lower portion of an outer shrink wrap cover for the battery
pack.
FIG. 5 is a front elevation view of a second embodiment of my novel
battery pack, with a transparent shrink wrap cell holder sleeve
body for one of two battery columns, showing a first shrink wrap
cell holder sleeve which contains a first column of battery cells,
a a second column of battery cells in which adjacent battery cells
are, at two joints, are affixed together with a short shrink wrap
tube, and, at two other joints, are affixed together with strapping
tape, and also having an outer shrink wrap cover for the battery
pack, shown with the battery pack holding ten battery cells.
FIG. 6 is a rear exploded perspective view, somewhat similar to the
battery pack just illustrated in FIG. 2, now showing the top and
bottom end caps, a first shrink wrap cell holder sleeve which
contains a first column of battery cells, a second column of
battery cells in which adjacent battery cells are, at two joints,
are affixed together with a short shrink wrap tube, and, at two
other joints, are affixed together with strapping tape, and in
which an outer shrink wrap cover is utilized for securing the
battery pack together.
FIG. 7 is a front cross-sectional view of the top end of my battery
pack as just illustrated in FIGS. 5 and 6, now showing the
electrical connection to positive terminals of a battery cell on
one side and to a negative terminals of a battery cell on the other
side, as well as the upper end of first shrink wrap cell holder
sleeve which contains a first column of battery cells, and the
upper portion of an outer shrink wrap cover for the battery
pack.
FIG. 8 is a front cross-sectional view of the bottom end of my
battery pack just illustrated in FIGS. 5, 6, and 7, now showing the
electrical connector bar used in the bottom end cap to connect a
first battery column with a second battery column, as well as the
bottom end of a first shrink wrap cell holder sleeve which contains
a first column of battery cells, and the lower portion of an outer
shrink wrap cover for the battery pack.
FIG. 9 is an end elevational view showing one method of assembly of
the embodiment of my battery pack just illustrated in FIGS. 5, 6,
7, and 8, showing the use of wooden spacer blocks above the top and
below the bottom end caps for installation of tightening bands,
such as rubber bands, cord or fishing line, and for spacing the
tightening bands away from the top and bottom end caps, during the
step of heating and shrink wrapping the outer shrink wrap cover;
after the shrink wrap cover is cooled and secured, the spacer
blocks and the tightening bands are removed.
FIG. 10 is a front elevation view of a third embodiment of my novel
battery pack, with a transparent shrink wrap cell holder sleeve
body used for each of two battery columns, a flush style top and a
flush style bottom end cap (each with electrical contacts), shown
with the battery pack holding ten battery cells, and utilizing a
strong tape, preferably filamented strapping type tape, for tightly
urging the battery cells together for efficient electrical supply
from the battery pack, and utilizing an outer transparent shrink
wrap cover for additional force to compact batteries together in
the pack.
FIG. 11 is a rear exploded perspective view of the battery pack
just illustrated in FIG. 10, showing the top and bottom end caps, a
first shrink wrap cell holder sleeve which contains a first column
of battery cells, a second shrink wrap cell holder sleeve which
contains a second column of battery cells, the start of winding
filamented strapping tape around the battery pack over the top and
bottom flush style end caps and along the longitudinal axis of the
battery pack, and the use of a transparent outer shrink wrap cover
for the battery pack.
FIG. 12 is a front cross-sectional view of the top of the
embodiment of my battery pack just illustrated in FIGS. 10 and 11,
now showing the electrical connection to positive terminals of a
battery cell on one side and to a negative terminals of a battery
cell on the other side, as well as the upper end of first shrink
wrap cell holder sleeve which contains a first column of battery
cells, the upper end of a second shrink wrap cell holder sleeve
which contains a second column of battery cells, the upper wrapping
of tape over the top end cap, and the upper portion of a
transparent outer shrink wrap cover for the battery pack.
FIG. 13 is a front cross-sectional view of the bottom end of my
battery pack just illustrated in FIGS. 10, 11, and 12, now showing
the electrical connector bar used in the bottom end cap to connect
a first battery column with a second battery column, as well as the
bottom end of a first shrink wrap cell holder sleeve which contains
a first column of battery cells, the bottom end of a second shrink
wrap cell holder sleeve which contains a second column of battery
cells, the bottom wrapping of tape under the bottom end cap, and
the lower portion of an outer shrink wrap cover for the battery
pack.
FIG. 14 is a vertical end view of the embodiment of the battery
pack just illustrated in FIGS. 10, 11, 12, and 13 above, now
showing the fully assembled battery pack with the filamented
strapping tape provided in secure, overlapping loop fashion, as
seen through a transparent shrink wrap cover and revealing a column
of five battery cells inside.
FIG. 15 is a partial cross-sectional view of the construction of
electrical connectors used for external connection to the battery
pack, showing the electrical contacts used, the preferred hollow
copper contacts, and the heavy flexible wire utilized.
FIG. 16 is a reflected plan view of the interior of one embodiment
of my end cap, showing the peripheral flange portions and the
interior end; the cap may be utilized for either a top end cap or a
bottom end cap by inserting appropriate electrical connectors.
FIG. 17 is a top plan view of the electrical connector bar used in
a bottom end cap to electrically connect the bottom battery in a
first column of batteries with the bottom battery in an second
column of batteries.
FIG. 18 is a side elevation view of the electrical connector bar
first illustrated in FIG. 17.
FIG. 19 is a perspective view of a flush type end cap, such as
shown in FIGS. 10, 11, 12, 13, and 14.
FIG. 20 is a top view of the flush type end cap just shown in FIG.
19.
FIG. 21 is a perspective view a fully assembled battery pack,
showing the use of strapping tape for tightly binding the battery
pack, the use of a pair of inner shrink wrap cell holder sleeves,
an outer shrink wrap layer, and the use of a hook and loop type
fastener material for affixing the battery pack to a desired
location in an machine which utilizes the battery pack.
FIG. 22 is a side elevation view of a battery pack, providing a
schematic illustrating the method of wrapping strapping tape around
a partially assembled battery pack in order to maximize the
strength of the resultant pack structure, in order to produce a
finished battery pack such as just illustrated in FIG. 21.
FIG. 23 is a front vertical cross sectional view of a battery pack,
similar to the view shown in FIG. 12, but now showing the use of a
"phantom" cell in lieu of one battery in the battery pack.
FIG. 24 provides a top view of the structure of the phantom cell
just shown in FIG. 23, taken looking down from line 24--24 of FIG.
25.
FIG. 25 provides a side elevation view of the "phantom" cell just
illustrated in FIGS. 23 and 24.
FIG. 26 is a top plan view of a thin, preferably adhesively backed
label for affixing to my battery pack, which is especially useful
in my repair kit for battery packs.
In the drawing, like structures are shown in the various figures
with like reference numerals without further mention thereof. Also,
similar structures are shown with the use of a prime (') or double
prime (") mark, and although the same name may be utilized for such
parts or structures, it is to be appreciated that the various
embodiments may be distinguished by the designations provided.
DESCRIPTION
I have now invented, and disclose herein, a novel solderless
battery pack for holding rechargeable battery cells. Importantly,
utilizing my novel battery packs in a method of operating
electrically powered vehicles, especially model aircraft and
automobiles, provides the significant benefits of increased battery
power and of extended battery life.
As seen in the embodiment depicted in FIG. 1, my battery packs 20
have in the central portion thereof a pair of elongated cell column
holder sleeves 22 and 23, for a first column C.sub.1 and a second
column C.sub.2 of battery cells 24, respectively. The cell holder
sleeves 22 and 23 are preferably provided in a shrink wrap material
which has a thin wall and a "see-through" optical property that
allows the user to see through the cell holder sleeves 22 and 23 to
confirm the visual appearance and the polarity orientation of each
of the battery cells 24 that are confined and contained by the cell
holder sleeves 22 and 23. More specifically, each of typical
battery cells 24 has a positive terminal 26 and a negative terminal
28 at opposing ends of an elongate and normally cylindrical body
portion 30 with outer surface 32. It is important that the positive
26 and negative 28 terminals in adjacent battery cells 24 be
properly oriented to avoid creating an electrical short circuit at
any pair of battery cells 24 in the battery pack 20.
As better seen in FIGS. 2, 3, and 4, the cell holding sleeves 22
and 23, when provided in battery pack 20 in a configuration to hold
a first C.sub.1 and a second C.sub.2 column of battery cells 24,
substantially resembles two extended cylinders placed side-by-side
extended along a common axis in a nip-roll type configuration. In
this configuration, a pair of side-by-side battery cell sleeve
holding tubes 22 and 23 are provided, each adapted for close
fitting, shrink wrap compression engagement around and securely
holding a plurality of battery cells 24 in a first battery cell
column C.sub.1 and in a second battery cell column C.sub.2,
respectively. Typically, a number of batteries P, where P is a
positive integer, usually from 2 to five are located in each of a
first C.sub.1 and in a second C.sub.2 column of battery cells.
However, a larger number of batteries in a column and more than two
battery columns in a battery pack are feasible in accord with the
teachings herein. While this technique is most advantageously
performed with rechargeable batteries, and often, sub-C type Ni-cad
batteries, it is also feasible and at times quite advantageous with
non-rechargeable batteries. Also, the methods and the structures
taught herein are applicable to other battery sizes, such as AA, or
AAA, or C size, and with other battery types, such as nickel metal
hydride, or lithium, etc., as well as with the aforementioned
Ni-cad type batteries.
Adjacent the first (upper or top as shown) end 34 and at the second
(lower or bottom as shown) end 36 of the battery cell sleeve
holding tubes 23 and 23, a high strength bottom end cap 40 and a
high strength top end cap 42 are affixed, respectively. As seen in
FIGS. 16, 17, and 18, inside the bottom end cap 40 is placed an
elongate copper connector bar 44, for connecting the lowermost
battery cell 24.sub.1(L) in a first column with the lowermost
battery cell 24.sub.2(L) in a second column. In this manner, the
first column C.sub.1 of battery cells is a series of longitudinally
co-axially oriented battery cells from lowermost cell 24.sub.1(L)
to uppermost cell 24.sub.1(L+X), where an integer X of quantity
P.sub.1 -1, and where P.sub.1 is a positive integer greater than
zero and representing the number of cells P.sub.1 in the first
column C.sub.1. Similarly, a second column C.sub.2 of battery cells
24 is a series of longitudinally co-axially oriented battery cells
from lower most cell 24.sub.2(L) to upper most cell 24.sub.2(L+Y),
where an integer Y of quantity P.sub.2 -1, where P.sub.2 is a
positive integer greater than zero and representing the number of
cells P.sub.2 in the second column. Additionally, while most
commonly the number of cells P.sub.1 in the first column is the
same as the number of cells P.sub.2 in the second column,
occasionally it will be advantageous to utilize an uneven number of
battery cells 24 between columns C.sub.1 and C.sub.2, and utilize a
phantom cell in lieu of a battery cell, as further depicted in
FIGS. 23, 24, and 25 below.
Also, it should be understood that while I have shown and explained
my battery pack by use of the most commonly encountered two column
configuration for battery cells, it is to be understood that any
convenient integral number C of columns, from a single column
(where the number of columns is C.sub.1, up to any desired quantity
of battery cell columns where C.sub.C), could be accomplished by
use of the techniques taught and claimed herein, by simply adding
the desired number of battery cell holder sleeves (the number of
sleeves provided match the desired number of columns), providing a
bottom end cap 40 and of the top end cap 42 in the required shape,
as well as providing electrical connectors in an appropriate
electrical contacting configuration.
Referring now to FIG. 16, it can be seen that top end cap 42 has an
interior end wall portion 53, and first and second electrical lead
line passageways defined by sidewalls 56 and 58. Also, as can be
seen in FIGS. 3, 5, and 7, for example, an exterior end wall
portion 54 is located opposite interior end wall portion 53. The
interior wall 60 of peripheral wall flange 62 (of thickness T)
extends outward from interior end wall portion 53 to cover and
confiningly contain at least that portion of the outer surface 32
of battery cell 24 which is adjacent the first or top end C.sub.1
(T) of the first column C.sub.1, and adjacent the first or top end
C.sub.2 (T) of a second column C.sub.2 of batteries 24. Similarly,
as can be appreciated by inspection of FIGS. 2, 4, and 6, the
bottom end cap 40 has an interior end wall portion 63, an exterior
end wall portion 64. For minimizing parts requirements, the bottom
end cap 40 may include unused first and second electrical lead line
passageways defined by sidewalls 66 and 68, in order that the part
can also be utilized as a top end cap 42. In other words, to
minimize costs, the top 42 and bottom 40 end caps may be molded
identically. In the bottom end cap 40, the interior wall 70 of
peripheral wall flange 72 extends outward from interior end wall
portion 63 to cover and confiningly contain at least that portion
of the outer sidewall 32 of battery cell 24 adjacent the bottom end
C.sub.1 (B) of first column C.sub.1, and adjacent the bottom end
C.sub.2 (B) of second column C.sub.2.
Preferably, for electrical connection between the positive terminal
26 at the bottom end C.sub.1 (B) of first column C.sub.1, and the
negative terminal 28 at the bottom end C.sub.2 (B) of second column
C.sub.2, an electrical connector bar 44 is added in the bottom end
cap 40. The bar 44 is placed in connector bar receiving indentation
45 (normally provided in both of the preferably identical molded
plastic portions of bottom 40 and top 42 end caps). The connector
bar 44 has a centrally located pocket or land portion 47 sized and
shaped complementary to the indentation 45, for secure engagement
of the connector bar 44 in its operating location. Usually, I
prefer a thin connector bar 44, such as about 1/32" in thickness
KK.
In the embodiment of my battery pack shown in FIGS. 1, 2, 3, and 4,
to help the user assure that polarity of batteries is correctly
maintained, the battery pack 20 preferably uses a first stay-bolt
80 and a second stay-bolt 82 which are not interchangeable, i.e.,
they are of different in configuration, so that they are not
reversible. To assure this arrangement is achieved, one ideal
configuration is to use stay-bolts of different diameter. I prefer
to use a first stay-bolt 80 of "all-thread" configuration in a
rather small diameter, such as a 4-40 size, and a different small
diameter "all-thread" second stay-bolt 82, preferably in the 2-56
size. Each of first 80 and second 82 stay-bolts are provided in a
length A and A' respectively. This length is suitable to
accommodate the overall length B of the battery pack 20, made up of
the length of the battery column C.sub.1 and the thickness of the
bottom 40 and top 42 end caps of a pre-selected size (i.e.,
including a desired type and number of battery cells 24 and top 42
and bottom 40 end cap design). Sometimes, it may be desirable that
one of the nuts on each stay-bolt, normally the bottom nut 84 on
the first stay-bolt 80, and the bottom nut 86 on the second
stay-bolt 82, can be permanently secured, to their respective
stay-bolts, to simplify removal and reattachment of the
stay-bolts.
As can be seen from comparing FIGS. 1 and 2 battery cells 24 in the
battery pack 20 are securely compressed for tight fitting
engagement of their respective positive 26 and negative 28
terminals, in a properly configured series polarity fashion,
by:
(a) inserting a first column C.sub.1 battery cells 24 in a battery
cell holder sleeve 22, carefully and properly aligning the polarity
to avoid a short circuit;
(b) inserting a second column C.sub.2 of battery cells 24 in a
battery cell holder sleeve 23, carefully and properly aligning the
polarity to avoid a short circuit;
(c) shrinking each of cell sleeve holders 22 and 23 so that the
cell sleeve holders are tightly griping and securing therein the
batteries 24 in each of the respective columns C.sub.1 and C.sub.2
;
(d) inserting the first stay-bolt 80 through the first stay passage
90, defined by sidewall 92 in bottom end cap 40,
(e) inserting second stay-bolt 82 through the second stay passage
94, defined by sidewall 96 in bottom end cap 40;
(f) inserting battery cell holder sleeves 22 and 23 into a confined
relationship with interior 70 of the peripheral flanged wall 72 of
the bottom end cap 40, carefully observing the polarity markings
"-" and "+",
(g) running first and second stay-bolts longitudinally along the
main axis of the battery pack;
(h) inserting the first stay-bolt 80 through the first stay passage
110 defined by sidewall 112 in top end cap 42, carefully observing
the polarity markings on the top end cap 42, and insuring that such
polarity markings agree with the orientation of the battery cells
in the cell holder sleeves 22 and 23, and that each of the first 80
stay-bolt and second 82 stay-bolt is inserted into the stay
passageway of proper size;
(i) inserting the second stay-bolt 82 through the second stay
passage 114, defined by sidewall 116 in top end cap 42;
(j) affixing top nut 120 to first stay-bolt and initially
tightening the nut 120 finger tight;
(k) affixing top nut 122 to second stay-bolt 82 and initially
tightening the nut 122 finger tight;
(l) tightening both top nut 120 and 122 in a balanced fashion to
bring substantially uniform pressure to both the first 80 stay-bolt
side and the second 82 stay-bolt side of both the top end cap 42
and the bottom end cap 40, so as to evenly and firmly apply
compressive force on a cell-to-cell basis, and from the uppermost
cell 24.sub.1(L+N) in the first column, and the upper most cell
24.sub.2(L+M) in the second column, to the respective positive
electrical lead line contactor and negative electrical lead line
contactor;
(m) covering the assembled product from the preceeding steps with
an outer shrink wrap tube 124, wherein the shrink wrap tube length
D is sized slightly longer than the aforementioned overall length B
of battery pack 20 (preferably about 0.25 inches overlap is
provided in the shrink wrap tube 124 at the top and also at the
bottom ends, i.e., [D+0.5 inches]=B); and
(n) shrinking the outer shrink wrap tube 124 to provide a
compressive force on the bottom end cap 40 by way of a bottom
overlapping ring 126 of shrink wrap thereon, and to provide a
compressive force on the top end cap 42 by way of a top overlapping
ring 128 of shrink wrap thereon.
For both the shrink wrap cell holder sleeves 22 and 23, as well as
for the outer shrink wrap tube 124, I prefer to utilize a
transparent plastic shrink wrap material of a preselected size as
may be obtained from RJI International Corporation, Reno, Nev., or
from a wide variety of other suppliers of shrink wrap material.
After the battery pack has been prepared, connectors K(+) and K(-)
are used to connect the positive and negative lead lines (discussed
below) to the apparatus being driven. For electrical connector K(-)
I prefer to use a black housing, model number 1327G6, and for
electrical connector K(+) I prefer to use a red housing, model
number 1327, and for both I prefer to utilizize electrical contacts
model number 1331, all from Anderson Power Products, a Division of
High Voltage Engineering, 145 Newton Street, Boston, Mass.
02135.
In FIG. 5, a second embodiment of my battery pack 20' is
illustrated. This FIG. 5 shows a front elevation view of a battery
pack 20' which utilizes a shrink wrap type cell holder sleeve 23 of
length R for one column C.sub.1 of batteries. I prefer to provide
the cell holder sleeve 23 length R such that the length R is less
than the overall column height C.sub.H by about the height of one
battery 24, so that about one-half of each of the bottom battery
23.sub.2 (L) and the top battery 23.sub.2 (L+X) is not covered by
the sleeve 23. Likewise, when a cell holder sleeve 22 is utilized
for column C.sub.1, a length R is utilized that is less than column
height C.sub.H of column C.sub.1 by about the height of one battery
24. Alternately, as shown in FIGS. 5 and 6, and which can be easily
understood from the perspective view of FIG. 6, either short
cylindrical tubes 127 of shrink wrap of width Q can be used to join
adjacent batteries 24. Alternately, short strips of adhesive tape
129 can be used to join adjacent batteries 24. Either of the
methods utilized for column C.sub.2 as just explained allows for
improved thermal conductivity, i.e. better cooling of batteries.
Moreover, it should be understood that in lieu of the just
described method for joining adjacent batteries in a column, the
"shrink wrap" method of preparing a battery pack 20', without the
use of stays (e.g., items 80 and 82 in FIG.2) can also be
accomplished by using, in each of the multiple columns (e.g.,
C.sub.1 and C.sub.2) for sets of battery cells 24, a thin-wall
battery cell holder shrink wrap sleeve 22 or 23 for each
column.
One method of building the battery pack 20' just illustrated in
FIGS. 5, 6, 7, and 8 is shown in FIG. 9. Here in FIG. 9, an end
elevational view shows the use of a wooden spacer block ST above
the top end cap 42, and a wooden spacer block SB below the bottom
end cap 40, for installation of tightening bands TB. The tightening
bands TB can be any convenient material for forming the appropriate
compression during installation of the outer shrink wrap 124, such
as rubber bands, cord or fishing line. The spacer blocks ST and SB
allow for spacing the tightening bands away from the top 42 and
bottom 40 end caps during the step of heating and shrinking the
outer wrap 124. After the outer shrink wrap 124 is cooled and
secured, the spacer blocks ST and SB, as well as the tightening
bands TB, are removed.
As noted in FIG. 26, to assist the user in keeping polarity of
batteries correct, I have found it useful to provide a label 95
with reference indicia 97 and 99 thereon (as well as "-" and "+"
terminal markings) so that both end caps and the batteries are be
properly assembled into a finished battery pack 20 or 20', for
example, when the user rebuilds the battery pack utilizing my
rebuild kit. The just mentioned reference indica are preferably
applied externally by affixing the label 95 near the middle of the
transparent outer shrink wrap tube 124.
Battery cells 24 must be properly prepared prior to inserting the
same into the shrink wrap type battery cell holding sleeves 22 and
23 of my Solderless Power Tube (tm) battery pack 20, 20', or 20" as
discussed below. For example, Sanyo brand 2000 milli-amp-hour
("mah") Sub-C cells have outer wrappings, and the top layer must be
removed in order that the positive and negative parts of adjacent
battery cells can touch each other when such cells are stacked into
a column C. For removing the top layer, the Sanyo brand cell should
be held with the bottom or negative side up, and the top covering
layer is slit and peeled from the cell. However, care must be taken
to prevent damage to the second or bottom wrap layer, as it is the
only protection against a short circuit. On the other hand,
Panasonic brand 1700 "mah" cells have only one outer covering
layer, and require no preparation for placement in my battery pack.
In any case, once the covering of the selected battery 24 is
properly configured, I recommend that the terminals on each battery
cell be properly cleaned by rubbing both the positive and the
negative terminals of each cell with "Scotch-Brite" (tm) brand
scouring pads, made by 3-M Corporation of Minneapolis, Minn., or
similar material. Steel wool should not be used, as it may have
deleterious effects, including the creation of short circuits.
Also, if damaged insulation is found on any of the selected battery
cells, it must be repaired before the cell is placed into the
battery pack 20, 20', or 20".
The Solderless Power Tube (tm) battery pack allows high current
flow, because the unique design provides the smallest possible
number of electrical connections. The connections which are present
are designed to carry high current with the smallest possible
resistance. The battery cells 24 touch each other, under
compression, in series in columns, with absolutely nothing in
between adjacent cells in the same column. Also, the cross-over
connection bar 44 between columns is preferably made of silver
plated copper, and is designed to carry a high current load. The
positive electrical contact 130 (affixed to the positive electrical
lead 132) and the negative electrical contact 134 (affixed to the
negative electrical lead 136) of the battery pack 20 are preferably
made of copper, also. As noted in FIG. 15, the positive and
negative lead lines 132 and 136, respectively, are preferably
provided in 14 gauge insulated copper wire 139 over which a hollow
cylindrical portion 140 and 142 of the positive 130 and negative
contacts 134, respectively, are crimped. Further, a "wave washer" W
(see FIGS. 2, 3, and 6, for example) is provided between each of
the positive and negative contacts and the interior wall 53 of the
top end cap 42, to keep the copper positive 130 and negative 132
contacts flat on their respective positive and negative contacts on
cells 24.sub.1 (L+Y) and 24.sub.2 (L+X) to assure that the most
efficient electrical connection possible is attained.
As just described, the opposing top and bottom end caps and the
thin walled shrink wrap type battery cell sleeves 22 and 23 are
secured together in a single battery pack 20 assembly. Compression
and security of the battery pack 20 package may be enhanced by use
of adjustably tightenable fasteners, preferably in the form of
stays, such as the all thread bolts above described. Also, it is
important to emphasize that preferably, the all-thread bolts are
each of different size, to aid in keeping the polarity of the
batteries correct. As noted above, I prefer to use a 4-40
all-thread bolt on one side, and a 2-56 all thread bolt on the
other side. Nuts of appropriate size are provided on either end of
the all thread bolts, above the upper end and below the lower end,
respectively, of the top 42 and bottom 40 end caps. The nuts are
tightened until the cells in the pack 20 are adequately compressed
together and against the contacts provided. As described, no solder
joints are used, and the battery power is efficiently provided to
the apparatus using the battery pack. Alternately, as further
described herinbelow, strapping tape can be utilized to provide a
compact, high efficiency, tightly bound battery pack.
For model cars, it is common to utilize six (6) Ni-cad type cells
24 in a battery pack 20. For model aircraft, it is more common to
utilize ten (10) or twelve (12) cells. In the later case, amperage
may range from ten (10) to eighty (80), depending upon the amount
of instantaneous work being done by the electric motor.
Especially in various competitive situations, where battery pack
limitations are prevalent, it is sometimes found that it is
desirable to place an odd number of batteries in a battery pack 20.
In such cases, a phantom cell 50 as shown in FIGS. 23, 24, and 25
can be utilized. Ideally, the phantom cell approximates in size and
shape one of the battery cells 24 being removed from the battery
pack 20. For heat dissipation, I prefer the use of a fluted design,
having multiple flutes F spaced about a central, preferably
cylindrically walled passageway P that allows an extended length
lead line 136' to pass therethrough. For increased cooling, a base
300 can be provided to space the phantom cell 50 upward from the
battery on which it sets. Also, tubular flanged bushing 302 can be
provided for locating electrical contacts, such as contacts 134',
below the phantom cell 50.
Turning now to FIG. 10, a front elevation view of a third
embodiment of my novel battery pack, designated as pack 20", is
provided. In this embodiment, a preferably transparent shrink wrap
cell holder sleeve body 22 and 23 is provided for each of two
battery columns C.sub.1 and C.sub.2. A flush style upper end cap
42' is provided, and a corresponding flush style lower end cap 40'
is provided. The flush style end caps, as further explained in
FIGS. 19, 20, and 21 below, allow the battery pack 20" to be
provided without an outwardly protruding ledge adjacent the
uppermost and lowermost batteries in the pack, due to the shape of
the end caps provided.
To firmly and securely fasten the battery pack 20", a strong,
stretch resistant tape, preferably filamented strapping type tape
400 is utilized for tightly urging the battery cells 24 together,
for efficient electrical supply from the battery pack 20". One
exemplary strapping tape is a filamented type strapping tape
manufactured by 3M of St. Paul, Minn., and is sold under the Scotch
Brand mark, #893, for both 0.75 inch wide and 0.5 inch wide
versions. The use of strapping tape is especially advantageous
since it eliminates the need for a mechanical stay, such as the
threaded rods described above and shown in FIGS. 1 and 2, thus
reducing part count, weight, and cost, as well as simplifies the
manufacture of my battery pack. In the embodiment shown in FIGS. 10
and 11 of my battery pack 20", in addition to tape 400, the outer
shrink wrap cover 124 provides yet an additional force, in the
manner described above, to compact batteries together in the pack
20". The complete longitudinally extending and top 42' and bottom
40' end cap encircling taping procedure which I prefer can be
conceptually envisioned from FIGS. 10, 11, and 21. However, in FIG.
22, one exemplary method of wrapping the strapping tape 400 is
detailed. The battery pack 20" is provided with columns of
batteries 24 already shrink wrapped with cylindrical shrink wrap
sleeves 22 and/or 23. Then, a first end 402 of tape 400 is affixed
at a starting point 404 inside the bottom end cap 40'. The tape 400
is affixed up the inside wall 406 of bottom end cap 40'. Then, the
tape is turned downward and affixed to a first outer wall 408 of
end cap 40'. Next, the tape 400 is turned to cover a strip across
the bottom 410 of bottom end cap 40'. Then, the tape is turned
upward along a second outer wall 412 of the bottom end cap 40'. The
tape is extended further upward tautly to the top end cap 42',
where the tape 400 is affixed to the first outer wall 414, then
across the top end 416, and down across a second outer wall 418.
Next, tape 400 is tautly stretched to the first outer wall 408 of
the bottom end cap 40', where a second tape layer 420 is applied
over a first tape layer 422 earlier affixed. Likewise, a second
tape 424 is applied to a first tape layer 426 on the bottom 410,
and to a first tape layer 428 on the second outer wall 418, to a
convenient end point 430. When the strapping tape 400 is tautly
applied as just described, then when the outer shrink wrap 124 is
applied and shrunk in place, those portions of the tape 400
extending between the end caps 40' and 42' are compressed,
increasing their tension, and further compressing the batteries 24
against each other, and increasing the compactness of the pack
20".
Further details of the embodiment similar to that just discussed
appear in FIGS. 12 and 13, where front cross-sectional top and
bottom views, respectively, are shown for the battery pack 20",
with the strapping tape 400 in place, over the top end cap 42' and
under the bottom end cap 40', and with the outer shrink wrap cover
124 fully compressed and in place. Note how, when utilizing the
flush type top end cap 42' and flush type bottom end cap 40' that
the shrink wrap 124 forms a slight concave impression 430 to
further grip the adjacent battery.
A fully assembled battery pack 201', the components of which have
just been described, is illustrated in FIGS. 14, where a vertical
end view is provided of a pack 200 with five battery cells in a
column C.sub.2. In FIG. 21 a perspective view is provided of a
battery pack 20" with four battery cells in each of columns C.sub.1
and C.sub.2. In both FIG. 14 and FIG. 21, strapping tape 400 is
seen through a transparent outer shrink wrap cover 124. Also, in
FIG. 21, the use of a hook and loop type fastener 450, adhesively
applied to the outer shrink wrap cover 124, is seen, for use with a
complementary hook and loop fastener in the device utilizing my
battery pack design.
Details of two embodiments of my end caps can be further understood
by comparison of FIGS. 16, 19, and 20. In FIG. 16, a reflected plan
view of the interior of a one embodiment of my end cap is provided;
this embodiment may be utilized for either a top end cap 40 or for
a bottom end cap 40, by inserting appropriate electrical
connectors. Likewise the end cap shown in FIGS. 19 and 20 can be
utilized as either a top end cap 42' or a bottom end cap 40', by
attachment of appropriate electrical connectors as described
herein. The perspective view provided in FIG. 19 illustrates the
flush type end cap, 40' or 42', as is also shown in FIGS. 10, 11,
12, 13, 14, 20, 21, and 23. In addition to first 408 and second 412
outer sidewalls, a gap G defined by edgewalls 460 and 462 is
provided for clearance of a selected battery 24, which is placed on
selected electrical contactors provided inside the base 464.
Ideally, outer sidewalls 460 and 462 extend for about a third of
the height 24.sub.H of an anticipated battery 24 size, although the
exact height of such sidewalls is not normally critical.
For repair purposes, I find it advantageous to provide a repair
kit, including a first cell holder sleeve 22, a second cell holder
sleeve 23, an outer shrink wrap cover 124, and a length of tape
400, so that the user can take my battery pack apart and replace
battery cells as desired, yet utilize all component parts as
originally provided. Also, a decal as indicated in FIG. 26 is
normally provided in my repair kit, to assist the user in assuring
that correct battery polarity is observed. This repair kit and the
technique of using the kit for troubleshooting and battery
replacement is especially useful in model racing activities.
It is to be appreciated that the novel battery pack provided by the
present invention is a significant improvement in the state of the
art of battery packs, especially for battery packs used for model
aircraft and autos. My novel battery pack, and the method of
employing the same in operation of model aircraft and the like, is
relatively simple, and it substantially improves the cost
effectiveness of the battery operations in apparatus which utilize
the same. It will be readily apparent to the reader that my novel,
battery pack device and the method of using the same may be easily
adapted to other embodiments incorporating the concepts taught
herein. Thus, the invention may be embodied in other specific forms
without departing from the spirit or essential characteristics
thereof. Therefore, the embodiments presented herein are to be
considered in all respects as illustrative and not restrictive. All
changes and devices which are described within the meaning and
range of equivalents of the disclosures set forth herein are
therefore intended to be embraced therein.
* * * * *